Mercury 240 Jet Drive User manual

1
B
MAINTENANCE
90-884822 DECEMBER 2001 Page 1B-1
IMPORTANT INFORMATION
Section 1B - Maintenance
Table of Contents
Specifications 1B-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Lubricant/Sealant 1B-2. . . . . . . . . . . . .
Maintenance 1B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Each Use 1B-3. . . . . . . . . . . . . . . . . . . . .
After Each Use 1B-3. . . . . . . . . . . . . . . . . . . . . . .
Every 10 Hours of Use or Once a Month 1B-3
Every 50 Hours of Use or Once a Month 1B-3
Every 100 Hours of Use or Once a Season 1B-3
Fuel System 1B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Line Inspection 1B-4. . . . . . . . . . . . . . . . . .
Water Separating Fuel Filter 1B-4. . . . . . . . . . .
Spark Plug Inspection 1B-5. . . . . . . . . . . . . . . . . . . .
Battery Inspection 1B-5. . . . . . . . . . . . . . . . . . . . . . .
Fuse Replacement 1B-6. . . . . . . . . . . . . . . . . . . . . .
Flushing Cooling System 1B-7. . . . . . . . . . . . . . . . .
Corrosion Protection 1B-7. . . . . . . . . . . . . . . . . .
Out-of-Season Storage 1B-8. . . . . . . . . . . . . . . . . .
Fuel System 1B-8. . . . . . . . . . . . . . . . . . . . . . . . .
Protecting Jet Pump Components 1B-9. . . . . .
Battery Storage 1B-9. . . . . . . . . . . . . . . . . . . . . .
Specifications
FUEL
SYSTEM Fuel Recommended Gasoline
Recommended Oil
Gasoline w/Oil Injection
Unleaded 87 Octane Minimum
TC-W3 Premium Plus 2 Cycle
Outboard Oil
IGNITION
SYSTEM Spark Plug Type Spark Plug Gap NGK BPZ8HS-10 0.040 in. (1.0 mm)
STARTING
SYSTEM Battery Rating 670 (Minimum) Marine Cranking Amps 520 (Minimum) Cold Cranking Amps
DRIVE
HOUSING Lubricant Capacity 24 fl. oz. (710 ml)
STATOR
ASSEMBLY Lubricant Capacity 19 fl. oz. (562 ml)

MAINTENANCE
Page 1B-2 90-884822 DECEMBER 2001
Special Tools
1. Grease Gun 91-37299A1

MAINTENANCE
90-884822 DECEMBER 2001 Page 1B-3
Maintenance
Before Each Use
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check the engine compartment and use your nose to detect any fuel fumes.
4. Check throttle, shift and steering system for binding or loose components.
After Each Use
1. Wash off all salt deposits with fresh water if operating in salt water.
2. Flush out the engine cooling system if operating in salt or polluted waters or sandy
locations.
Every 10 Hours of Use or Once a Month
1. Check bilge siphon system.
2. Inspect cable bellows: worn, rubbing, or leaking.
3. Inspect battery and connections.
4. Check tightness of bolts, nuts and other fasteners.
Every 50 Hours of Use or Once a Month
1. Check level and condition of drive housing and stator lubricant.
2. Check corrosion control anodes.
3. Check tightness of bolts, nuts and other fasteners.
Every 100 Hours of Use or Once a Season
1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Replace spark plugs at first 100 hours or first year. After that, inspect spark plugs every
100 hours or once yearly. Replace spark plugs as needed.
3. Drain and replace drive housing lubricant.
4. Drain and replace stator housing lubricant.
5. Remove impeller and lubricate impeller shaft with 2-4-C with Teflon to prevent impeller
from seizing to the shaft.
6. Remove engine deposits by adding described amount of Quickleen to the fuel tank.
7. Replace engine fuel line filter.

MAINTENANCE
Page 1B-4 90-884822 DECEMBER 2001
Fuel System
WARNING
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or al-
low open flames or sparks in the area while servicing any part of the fuel system.
Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain
the fuel system completely. Use an approved container to collect and store fuel. Wipe up
any spillage immediately. Material used to contain spillage must be disposed of in an ap-
proved receptacle. Any fuel system service must be performed in a well ventilated area. In-
spect any completed service work for sign of fuel leakage.
Fuel Line Inspection
Visually inspect the fuel line for cracks, swelling, leaks, hardness, or other signs of deteriora-
tion or damage. If any of these conditions is found, the fuel line must be replaced.
Water Separating Fuel Filter
NOTE: The warning system will turn on when water in the fuel filter reaches the full level.
1. This filter removes moisture and also debris from the fuel. If the filter becomes filled with
water, the water can be removed. If the filter becomes plugged with debris, the filter must
be replaced with a new filter.
b
a
59226
a-Fuel/Water Separating Filter b-Water Sensor Lead
Remove and replace filter as follows:
a. Turn ignition key switch to OFF position.
b. Disconnect water sensor lead at bottom of filter.
c. Remove filter by turning the filter in the direction of the arrow (clockwise). Tip the filter
to drain fluid in a suitable container.
d. Lubricate the sealing ring on the filter with oil. Thread on the filter and tighten secure-
ly by hand. Reconnect the wire to the filter.
IMPORTANT: With the key switch in the RUN position, the fuel lift pump will fill the
filter with fuel. Visually inspect for fuel leakage from the filter. If leakage is observed,
turn key switch to the OFF position. Remove filter and inspect sealing ring/surface
for damage or debris.

MAINTENANCE
90-884822 DECEMBER 2001 Page 1B-5
Spark Plug Inspection
Inspect spark plugs at the recommended intervals.
1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. Inspect
spark plug boots and replace if cracked.
2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.
3. Set the spark plug gap. See Specification Chart in General Information Section.
4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs fin-
ger tight, and tighten 1/4 turn or torque to 20 lb. ft. (27 Nm).
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting capa-
bility.
IMPORTANT: Read the safety and maintenance instructions which accompany your
battery.
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive
and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.

MAINTENANCE
Page 1B-6 90-884822 DECEMBER 2001
Fuse Replacement
IMPORTANT: Always carry spare SFE 15 and 20 AMP fuses.
The electrical wiring circuits on the jet powerhead are protected from overload by fuses in
the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause
is not found, the fuse may blow again.
1. Open the fuse holder and look at the silver colored band inside the fuse. If band is bro-
ken, replace the fuse. Replace fuse with a new fuse with the same rating.
2. The fuses and circuits are identified as follows:
a. Smart Craft Data Bus Circuit – SFE 15 AMP Fuse.
b. Accessories – SFE 20 AMP Fuse.
c. Ignition Coil Circuit – SFE 20 AMP Fuse.
d. Electric Fuel Pump/ECM Driver Power/Oil Pump Circuit – SFE 20 AMP Fuse.
57777
ab
c
d
15
59221

MAINTENANCE
90-884822 DECEMBER 2001 Page 1B-7
Flushing Cooling System
Flushing the cooling system is essential after each use in salt water, after the boat has run
aground, or when the overheat warning horn sounds (possible debris in jet powerhead).
1. Locate the flush adapter in the boat. Some boats may have the adaptor mounted in the
hull or mounted in the engine compartment. Remove flush adaptor plug and attach wa-
ter hose.
a
b
a-Flush Adapter Plug Mounted on Hull
b-Flush Adapter Plug Mounted in Engine Compartment
2. The engine may be run using the Flushing Attachment: DO NOT run the engine above
idle speeds.
3. Turn water on and flush engine block for at least 10 minutes.
4. Remove water hose and install flush adaptor plug.
5. Flush outer surfaces of pump with water stream.
Corrosion Protection
The jet drive has three corrosion control anodes. One of the anodes is installed on the bot-
tom of the nozzle, one installed on the reverse gate and one is installed under the rudder.
a
a-Corrosion Control Anodes

MAINTENANCE
Page 1B-8 90-884822 DECEMBER 2001
Out-of-Season Storage
WARNING
As a safety precaution, when boat is in storage, remove positive (+) battery cable.
This will eliminate possibility of accidental starting of engine and resultant over-
heating and damage to engine from lack of water.
In preparing for out-of-season storage, two precautions must be considered: 1) The engine
must be protected from physical damage caused by freezing trapped water and 2) the en-
gine must be protected from rust, corrosion and dirt.
If the length of storage time between each use varies from 1 week to 2 months, it is recom-
mended to add Fuel System Treatment and Stabilizer to the fuel tank regularly each time
gasoline is added following the recommended amount as described on the Fuel Stabilizer
container.
The following storage procedures should be followed to prepare the Jet Drive for out-of-sea-
son storage or prolonged storage (two months or longer).
CAUTION
Never start or run the Jet Drive without water circulating through the cooling sys-
tem to prevent damage to the unit.
Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a forma-
tion of acid during storage and can damage the fuel system. If the gasoline being
used contains alcohol, it is advisable to drain as much of the remaining gasoline as
possible from the fuel tank, remote fuel line, and engine fuel system.
The most effective method for storage preparation is to add the recommended amount of
Fuel System Treatment and Stabilizer and Quickleen products as described on their con-
tainers to the fuel tank before the last operation of the boat. Adding Fuel System Treatment
and Stabilizer will help prevent the formation of varnish and gum in the gasoline. The Quick-
leen product will help clean and lubricate the fuel injectors.
To properly prepare the engine for prolong storage:
a. Drain the fuel from the Vapor Separator Tank (VST) into a suitable container by re-
moving the drain plug. After the fuel has been drained, reinstall the drain plug.
b. Remove the water separator fuel filter and empty the fuel into a suitable container.
Discard both the fuel and the filter properly.
c. Premix the following in a container:
(1.)0.68 oz (20 cc) or 2 tablespoons of Premium Plus Outboard oil or 2-Cycle Out-
board Oil.
(2.)0.27 oz (8 cc) or 2 teaspoons of Quickleen lubricant.
(3.)0.27 oz (8 cc) or 2 teaspoons of Fuel System Treatment and Stabilizer.
d. Pour this mixture in the new water separator fuel filter.
e. Reinstall the filter.
f. Prime the fuel system as outlined in the STARTING PROCEDURES.
g. Using a flushing attachment, start the engine and allow the engine to run at idle
speeds for 3 minutes.

MAINTENANCE
90-884822 DECEMBER 2001 Page 1B-9
h. Turn the engine off. Turn the water off if using a flushing attachment. Allow the water
to drain out of the unit completely.
i. Complete the other recommended items for storage.
Protecting Jet Pump Components
IMPORTANT: Check and refill housing with Premium Gear Lubricant before storage
to protect against possible water leakage into housing which is caused by loose lu-
bricant vent or fill plug. Inspect gaskets under lubricant vent and fill plugs replacing
any damaged gaskets before reinstalling plugs.
1. Drain and refill drive housing unit and stator assembly with Premium Gear Lubricant as
explained in “Jet Pump” section (see Table of Contents).
2. Lubricate all lubrication points.
Battery Storage
1. Remove battery as soon as possible and remove all grease, sulfate and dirt from top
surface.
2. Cover plates with distilled water, but not over 3/16 in. (5 mm) above perforated baffles.
3. Cover terminal bolts well with grease.
4. Store battery in a cool, dry place in a dry carton or box.
5. Remove battery from storage every 60 days. Check water level and place on charge for
5 to 6 hours at 6 amperes. DO NOT fast charge.
CAUTION
A discharged battery can be damaged by freezing.